Repair Broken Kohler Flywheel Magnets to Fix Charging System 

Good job Taryl I've been working on mowers for 40 yrs I think we're a dying breed Most young guys if they didn't have Google they be lost. If they had use microfich cards. Game over.

I have this problem a mont ago a replace that battery and today again but I haven’t done anything I wonder if is my voltaje regulator or my alternator start or on my Ezmark whit 22 hp kholer engine

This worked on my Kohler engine on a Dixie chopper i repaired just as shown here.

Hi Robert, Thanks for your input. I have one broken magnet. Good to know that I can glue both halves back on the flywheel in the proper sequence and get it to work. John

@WHATS YOURSOC Update: I glued the broken magnets back on the flywheel with JB Weld and now the charging system works perfect. Thanks to Robert Hills for sharing his knowledge. John

Broken magnet.... About to put it together... Now that I know that it works... Thank you for the extra info. Appreciate it.

It works great. 43 volts AC. Thank you.

Yeah, I experience the same scenario: I look for good DIY help videos and I can't find "the one"; usually I have to create a playlist and save about 20 videos until I understand the solution then after I move forward to do my best then when I return to RU-vid searching for another DIY Assistance video then occasionally in the "RU-vid Recommend List is the best video"!

+Tony Varga Great to hear Tony! And there's your dinner!

Thanks Tyral, I also had a broken magnet. I just spaced the magnets as shown i.e alternating North South poles and glued them with JB Quick to the inner face of the flywheel with the 1/8 inch recess from the top inner face of the flywheel. The one that was cracked I just placed the two pieces together where it was cracked and glued them to the flywheel. Got good A/C readings from the Stator and also good D/C readings from the center tap on the voltage regulator. John

Metal spacers can weaken mag field.

Not only that but you should never hit one of these Kohler command engines flywheels or the older Tecumseh cast iron engine flywheels with a hammer because that will knock the magnets off from the flywheel. The right tool to use is a harmonic balance puller or what I use which is a 5 ton hydraulic puller. Taryl you know better than that! but if even one is already off from the flywheel then take a hammer and hit the back side of the flywheel with a hammer where each magnet is. That will pop the rest off from the flywheel. Now I found that the best thing to use to do these magnets is a wire wheel in a drill to clean the inside of the flywheel and the backside of each magnet. Then get some acetone to clean it or gasoline. then you get your Best ones for vibration and high heat which are 2047 green, 266 red/orange, red 2700NA or RED 2760. You can also use 272 red or 277 red. The 266 red-orange is very high strength and heat up to 232c which is 450 degrees hot and handles high vibration or use the GREEN (Taryl already knows the one high heat green 2047 is heat resistant and very strong) loctite. that green requires a torch to remove the fastener. lol. Ive seen Taryl use the green before. lol. Put a thin coating over the back of each magnet setting them into their proper place as He shows. Then go set the flywheel in a warm 70 to 80 degree area (for faster set up) and you wont be able to pull that magnet off without it breaking after 24 hours of drying time. I know because I tried to remove them before and they will not come off without breaking by way of either screwdriver prying on a magnet OR hitting the backside of the flywheel with a hammer. I gave one a blunt hit with a hammer and it popped off in tiny pieces only. It was a junk flywheel. This was way back in the day. I was testing to see which was the best of like everything for holding these dam things in place. Specially on these dang Kohlers like this one here he just fixed. I got a dam exmark I have to do and that is going to be a big pain in the rear because of it having two shafts on it. Got to remove the pto adapter shaft from the flywheel side first after taking the belt off that runs the hydro pumps. Don't know what Crowler used to glue these in back in the day but it is way worse than what tecumish (as how Taryl would say it. lol. ) used. 56 years old and I too Own a small engine salvage as well. Done hundreds of these this way and never had one give way later or received even one complaint from a customer. I am a old Tecumish. lol. business seller of 39 years before they went out of business. Use to know like almost all the part numbers in my head of the cast iron old engines. kind of foggy now these days. lol.

Your hitting the bolt thats not touching the flywheel because the bolt was reinstalled loose. I worked in a john deere dealer out of 7 mechanics all of them did the pry bar hammer method. Bunch of nervous Nellie's out there that obviously have no experience.

Hey

My magnets are broken and missing pieces. Could you please help me find the ones you used?